KTM 250 sxf 2016 Motocross Bike Manuals

Manuals and User Guides for KTM 250 sxf 2016 Motocross Bike. We have 1 KTM 250 sxf 2016 Motocross Bike manual available for free PDF download: Repair Manual

KTM 250 sxf 2016 Repair Manual (307 pages)

Brand: KTM | Category: Motorcycle | Size: 67 MB

Table of Contents
3
Means of Representation
7
Symbols Used
7
Formats Used
7
Safety Advice
8
Important Notes
9
Manufacturer and Implied Warranty
9
Operating and Auxiliary Substances
9
Spare Parts, Accessories
9
Serial Numbers
10
Chassis Number
10
Type Label
10
Engine Number
10
Raising the Motorcycle with a Lift Stand
11
Removing the Motorcycle from the Lift Stand
11
Starting
11
Starting the Motorcycle to Make Checks
12
Fork, Triple Clamp
13
Sx-F Eu
13
Air Suspension AER 48
13
Adjusting the Fork Air Pressure
13
Adjusting the Compression Damping of the Fork
14
Adjusting the Rebound Damping of the Fork
14
Bleeding the Fork Legs
15
Cleaning the Dust Boots of the Fork Legs
15
Removing the Fork Legs
15
Installing the Fork Legs
16
Removing the Fork Protector
17
Installing the Fork Protector
17
Servicing the Fork
17
Disassembling the Fork Legs
17
Disassembling the Air Cartridge
21
Disassembling the Shock Absorber Cartridge
22
Checking the Fork Legs
24
Fork/Triple Lamp
25
Assembling the Shock Absorber Cartridge
25
Assembling the Air Cartridge
26
Assembling the Fork Legs
28
Greasing the Steering Head Bearing
33
Removing the Lower Triple Clamp
33
Installing the Lower Triple Clamp
34
Checking the Steering Head Bearing Play
35
Adjusting the Play of the Steering Head Bearing
36
Changing the Steering Head Bearing
36
Sx-F Us
38
Disassembling the Piston Rod
45
Disassembling the Hydrostop Unit
46
Disassembling the Seal Ring Retainer
47
Assembling the Seal Ring Retainer
48
Assembling the Hydrostop Unit
48
Assembling the Piston Rod
49
Assembling the Cartridge
50
XC-F Us
60
Handlebar Position
83
Adjusting the Handlebar Position
83
Adjusting the Basic Position of the Clutch Lever
83
Checking the Throttle Cable Routing
84
Checking the Play in the Throttle Cable
84
Adjusting the Play in the Throttle Cable
85
Changing the Footrests
86
Adjusting the High-Speed Compression Damping of the Shock Absorber
87
Adjusting the Low-Speed Compression Damping of the Shock Absorber
87
Adjusting the Rebound Damping of the Shock Absorber
88
Measuring Rear Wheel Sag Unloaded
89
Checking the Static Sag of the Shock Absorber
89
Checking the Riding Sag of the Shock Absorber
90
Adjusting the Spring Preload of the Shock Absorber
90
Adjusting the Riding Sag
91
Removing the Shock Absorber
91
Installing the Shock Absorber
93
Checking the Shock Absorber Linkage
94
Servicing the Shock Absorber
96
Removing the Spring
96
Disassembling the Damper
97
Changing the Pilot Bushing
100
Checking the Damper
100
Removing the Heim Joint
101
Installing the Heim Joint
102
Assembling the Damper
104
Bleeding and Filling the Damper
106
Filling the Damper with Nitrogen
108
Installing the Spring (SX-F EU)
109
Installing the Spring (SX-F US)
110
Installing the Spring (XC-F US)
111
Checking the Swingarm Bearing for Play
112
Removing the Swingarm
113
Installing the Swingarm
114
Changing the Swingarm Bearing
116
Removing the Main Silencer
119
Installing the Main Silencer
119
Changing the Glass Fiber Yarn Filling of the Main Silencer
119
Exhaust
120
Removing the Air Filter Box Cover
121
Installing the Air Filter Box Cover
121
Removing the Air Filter
121
Installing the Air Filter
122
Cleaning the Air Filter and Air Filter Box
122
Sealing the Air Filter Box
123
Securing the Air Filter Box Cover
123
Opening the Filler Cap
124
Closing the Filler Cap
124
Removing the Seat
125
Mounting the Seat
125
Removing the Fuel Tank
125
Installing the Fuel Tank
126
Checking the Fuel Pressure
127
Changing the Fuel Pump
128
Changing the Fuel Filter
130
Changing the Fuel Screen
132
Removing the Front Fender
134
Installing the Front Fender
134
Removing the Start Number Plate
134
Installing the Start Number Plate
135
Checking the Tire Air Pressure
136
Checking the Tire Condition
136
Checking the Wheel Bearing for Play
136
Checking the Brake Discs
137
Checking the Spoke Tension
137
Removing the Front Wheel
138
Installing the Front Wheel
139
Changing the Front Brake Discs
139
Changing the Front Wheel Bearing
140
Removing the Rear Wheel
141
Installing the Rear Wheel
141
Changing the Rear Brake Discs
142
Changing the Rear Wheel Bearing
142
Checking the Chain Tension
144
Adjusting the Chain Tension
144
Checking the Chain, Rear Sprocket, Engine Sprocket and Engine Guide
145
Checking for Chain Dirt Accumulation
148
Cleaning the Chain
148
Changing the Drivetrain Kit
148
Changing the Main Fuse
152
Removing the Battery
152
Installing the Battery
153
Checking the Charging Voltage
154
Checking the Open-Circuit Current
154
Checking the Capacitor
155
Checking the Starter Relay
155
Checking the Front Brake Linings
156
Changing the Front Brake Linings
156
Checking the Free Travel of the Hand Brake Lever
157
Adjusting the Basic Position of the Hand Brake Lever
158
Checking the Front Brake Fluid Level
158
Adding Front Brake Fluid
159
Changing the Front Brake Fluid
160
Checking the Rear Brake Linings
161
Changing the Rear Brake Linings
161
Checking the Free Travel of Foot Brake Lever
163
Adjusting the Basic Position of the Foot Brake Lever
163
Checking the Rear Brake Fluid Level
163
Adding Rear Brake Fluid
164
Changing the Rear Brake Fluid
165
Removing the Engine
167
Installing the Engine
173
Engine Disassembly
179
Removing the Clutch Push Rod
180
Draining the Engine Oil
180
Removing the Oil Filter
180
Gear Position Sensor, Removing
181
Spark Plug, Removing
181
Removing the Valve Cover
181
Starter Motor, Removing
182
Positioning the Engine at Ignition Top Dead Center
183
Removing the Timing Chain Tensioner
183
Removing the Camshaft
183
Cylinder Head, Removing
184
Removing the Piston
184
Rotor, Removing
185
Starter Drive, Removing
185
Removing the Suction Pump
186
Water Pump Impeller, Removing
186
Clutch Cover, Removing
187
Removing the Clutch Discs
187
Removing the Clutch Basket
188
Removing Primary Gear/Timing Chain/Force Pump
189
Removing the Force Pump
189
Removing the Locking Lever
190
Shift Drum Locating Unit, Removing
190
Shift Shaft, Removing
190
Left Engine Case, Removing
191
Shift Rails, Removing
191
Spacer, Removing
191
Removing the Shift Drum
192
Shift Forks, Removing
192
Removing the Transmission Shafts
192
Removing the Crankshaft
192
Work on Individual Parts
193
Working on the Right Section of the Engine Case
193
Working on the Left Section of the Engine Case
194
Work on the Clutch Cover
195
Checking the Oil Pressure Regulator Valve
196
Checking the Lubrication System
197
Removing the Crankshaft Bearing Inner Race
198
Installing the Crankshaft Bearing Inner Race
198
Connecting Rod, Conrod Bearing, and Crank Pin, Changing
198
Checking the Crankshaft Run-Out at the Bearing Pin
200
Measuring the Crankshaft End Play
200
Removing the Drive Wheel of the Balancer Shaft
201
Installing the Drive Wheel of the Balancer Shaft
201
Cylinder - Nikasil Coating
201
Checking/Measuring the Cylinder
201
Piston, Checking/Measuring
202
Measuring the Piston/Cylinder Mounting Clearance
203
Checking the Piston Ring End Gap
203
Camshafts, Checking
203
Checking the Pivot Points of the Camshafts
203
Valves, Removing
204
Valves, Checking
205
Valve Springs, Checking
206
Checking the Valve Spring Seat
206
Checking the Cam Lever
206
Checking the Cylinder Head
206
Valves, Installing
207
Checking the Freewheel
208
Freewheel, Removing
208
Freewheel, Installing
208
Checking the Electric Starter Drive
209
Checking the Timing Assembly
210
Preparing the Timing Chain Tensioner for Installation
211
Clutch, Checking
211
Shift Mechanism, Checking
213
Preassembling the Shift Shaft
214
Main Shaft, Disassembling
214
Disassembling te Countershaft
216
Transmission, Checking
217
Main Shaft, Assembling
220
Countershaft, Assembling
221
Engine Assembly
223
Installing the Crankshaft
223
Installing the Transmission Shafts
224
Shift Forks, Installing
224
Installing the Shift Drum
224
Shift Rails, Installing
225
Left Engine Case, Installing
225
Spacer, Installing
226
Shift Shaft, Installing
226
Shift Drum Locating Unit, Installing
226
Locking Lever, Installing
226
Installing the Suction Pump
227
Installing the Timing Chain
228
Primary Gear, Installing
228
Installing the Clutch Basket
229
Installing the Clutch Discs
230
Clutch Cover, Installing
230
Water Pump Cover, Installing
231
Starter Drive, Installing
231
Installing the Rotor and Ignition Pulse Generator
232
Installing the Piston
232
Cylinder Head, Installing
234
Installing the Camshafts
234
Installing the Timing Chain Tensioner
235
Checking the Valve Clearance
235
Adjusting the Valve Clearance
236
Starter Motor, Installing
236
Installing the Valve Cover
237
Spark Plug, Installing
238
Gear Position Sensor, Installing
238
Installing the Oil Filter
238
Oil Screen, Installing
239
Installing the Clutch Push Rod
239
Removing the Engine from the Engine Assembly Stand
240
Checking/Rectifying the Fluid Level of the Hydraulic Clutch
241
Changing the Hydraulic Clutch Fluid
241
Cooling System
242
Checking the Antifreeze and Coolant Level
242
Checking the Coolant Level
242
Draining the Coolant
243
Refilling Coolant
243
Lubrication System
244
Oil Circuit
244
Checking the Engine Oil Level
244
Changing the Engine Oil and Oil Filter, Cleaning the Oil Screen
245
Adding Engine Oil
247
Checking the Engine Oil Pressure
247
Ignition System
249
Ignition Coil - Checking the Secondary Winding
249
Checking the Spark Plug Connector
249
Alternator - Checking the Stator Winding
249
Removing the Stator and Crankshaft Position Sensor
250
Installing the Stator and Ignition Pulse Generator
250
Throttle Valve Body
255
Adjusting the Idle Speed
255
Executing the Initialization Run
255
Technical Data
256
Engine Tolerance, Wear Limits
257
Engine Tightening Torques
257
Capacities
259
Chassis
259
Electrical System
260
Tires
260
Fork
260
Shock Absorber
261
Chassis Tightening Torques
263
Cleaning the Motorcycle
265
Storage
266
Putting into Operation after Storage
266
Service Schedule
267
All SX-F Models Wiring Diagram
269
XC-F US Wiring Diagram
275
Substances
281
Brake Fluid DOT 4/DOT 5.1
281
Coolant
281
Engine Oil (SAE 10W/50)
281
Multi-Purpose Grease
282
Shock Absorber Fluid
282
Super Unleaded
282
Auxiliary Substances
283
Special Tools
286
Standards
300
List of Abbreviations
301
Index
302

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KTM 250 sxf 2016 Repair Manual (307 pages)

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